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.| G. coPEMAN MATCH PLATE PATTERN Filed July l1. 1925 4 Sheets-Sheet 1 INVENTOR.

May l, 1928. 1,667,722

L. G. coPEMAN v MATCH PLATE PATTERN Filed July l1. 11.925A 4 She-ets--Shee'c` INVENTOR-- Tioga? bye/)nn ATTORNEY.

1,667,722 L. G. COPEMAN MATCH PLATE PATTERN Filed July l1. 1925 4 Sheets-Sheet 5 Mayl. 1928.

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.A f.... A1 s l u .Many 11 1928. 1,667,722 l.. G. coPEMAN l MATCH PLATE PATTERN Filed July 11. 1925 4 Sheets-sheet 4 @if jm,

Patented May l, 1928.

UNITED STATES PATENT OFFICE.

ELOYD G. COIPEMAN, OF FLINT, MICHIGAN, ASSIGNOR T0 COPEMAN LABOBATOBES COMTA OF FLINT, MICHIGAN, A CORPORATION F MICHIGAN.

MATCH-PLATE PATTERN.

Application filed July 11, 1925. Serial No. 42,940.

This invention relates to a cast stone pattern, and is particularly adapted to that form vof patterns known as match-plate pat-v terns. In my copending application, Serial 5 No. 32,325, I describe and claim a pattern provided with a metal match plate on which the stone pattern is cast. It is the The use o a fairly strong wire mesh rei iniorcement may be often advantageously used in place of the metal plate described in my copending application. One advantage is that the wire mesh may be more easily v bent to conform to the parting line of the pattern and ortions of the wire mesh may be more' rea ily struck out for Athe purpose of reinforcing projecting portions oi the cast stone pattern. I n the drawings:

Fig. 1 is an elevation of a master pattern.

Fig. 2 is a cross section through a mould flask showing the master pattern placed therein, sand packed around the pattern up to thel arting line and stone poured over the san and pattern.

Fi 3 is a cross section showing the next step 1n the process.

FFig. 4 is a section on the line 4-4 of Fig. 5 is a cross section through one of the stone moulds.

Fig. 6 is a erspective view of a spacing frame adapted) to be inserted between the moulds when casting the match plate pattern.

Fig. 7 is a perspective view of the wire mesh reinforcement.

Fig. 8 is a cross sectional view through the moulds, showing the spacing frame therebetween and the stone poured into the mould for forming the pattern.

Fig. 9 is a section through the pattern removed from the mould.

Fig. 10 is a detailed section showlng the dowel pin holes.

Fig. 11 is a section on the hne 11-11 of Fig. 8.

Fig. 12 is' an edge elevational view of the pattern.

Fig. 13 is a. plan view of the wire mesh reinforcement showing the same split.

Flg. 14 is a sectional detail through a. l5 mould showing a metal plug fitted into a. recess of the mould.

Fig. 15 is a similar section but showing the stone poured in the mould for casting the pattern and securing said metal fixture or plug to the pattern.

In my copending application, Serial No. 33,648, I describe a method of making match plate patterns and that method is somewhat similar to the method em loyed here. Here the wood pattern is pre erablytaken and placed in plaster of Paris and a stone casting of the pattern is made. This is what I term the master pattern. The stone mould sections are formed in the same way T0 as before. The first stone mould section is formed by taking the master pattern a and placing it in a mould box b, and then packing sand in the box up to the parting line, as clearly shown in Fig. 2. A. parting material is then spread over the pattern and sand, and a plastic stone composition material is poured in the box over the sand and master pattern. Pins c are set in the sand and the stone d is poured around these pins for providing dowel pin holes. When this stone is allowed to set it is withdrawn from` the iiask and the sand is removed.

This stone mould section with pattern setting in it is now placed in another flask, suitable parting material spread over the surface of the stone and the pattern and a second mould section is formed by pouring a plastic stone over this pattern and stone mould section first made. When this stone is allowed to set the same may be withdrawn, thus completing -a pair of mould sections in which a part of the master pat-v tern is formed in each section. Such a mould section is shown in Fig. 5.

I prefer to use for this artificial stone an oxychloride cement and I preferably use the following proportions which, I ind, reduce a satisfactory stone when allowed to arden. Iuse 20% of magnesium oxide by weight, 100

30% of silica (powdered quartz) by wei ht, and 50% of finely` powdered 50-mesh si ica sand by weight. To this dry mix I add sufficient ma nesium chloride in solution to form a p astic stone material that may be readily poured.

From now on the process differs from the process described in my copending application Serial No. 33648. I take a spacing frame d which is cut out as at e to conform to the outline desired for my finished pattern. I then cut a piece of heavy wire mesh, designated f, to conform to the cut-out portion of the frame al (see Fig. 7). I secure in this wire mesh f the metal plugs g, so that they will project above and below the wire mesh and have a total height the same as the thickness of the frame d. This spacing frame which may be of metal or wood is arranged to be placed between the two mould sections, 'as shown in Fig. 11, to space the mould sections apart. This wire mesh is laid on one of the mould sections and is bent as'at lz. to conform to the parting line of the pattern. l These mould sections'are provided with the mould cavities z', these cavities forming projections on the final product that might be broken oli' unless the same are suitably reinforced. I s lit the wire mesh reinforcement as at ig. 13) along the mould cavity. Then I bend the mesh in at each side to project the same in the mould cavity z' (see Fig. 11). Where there are depressions in the mould on opposite sides, I may use an additional piece of wire mesh fm. which may be bent so that the same will project within the recesses on the opposite side of the wire mesh reinforcement. It would be ossible, however, to use'two wire mesh rein orcements and strike out portionsv Aof the same so that the struck-out portions of one wire mesh reinforcement will lie in one mould recess and the struck-up portionsv of the second wire mesh reinforcement will project within the mould. recesses opposite the first mentioned mould recess.

The rst step in the process is to lay the mould sections out and paint or spray them with a thin stone mix and then pour a stone mix in any deep recesses as at 10 (see Fig. 5) to avoid air pockets. Vbers 11 such as studs, screws or the like may then be set in if necessary. Instead of splittin and bending the wire mesh first, it cou d be laid on the mould section at this time andsplit and bent along the mould cavity as above described. lThe other mould section is partially lled, and reinforcements set in if necessary. When the stone has partially set so as not to dislodge the two sections are turned up together, the spacing` frame and reinforcment set in between the two sections, and more of the mix is piled in and then the mould sections are squeezed together, which squeezes outany Reinforcing memexcess stone and the pattern is permitted to set'and harden before removing from the mould. In this process I prefer to use a thick mix in which libre is mixed in. I preferably use a mix composed of magnesium oxide 25%, silica (powdered quartz)l 30%, ground asbestus fibre 3%, and 50-mes silica sand 42%. To this dry mix is added suicient magnesium chloride in solution at 26 Baume density to make the desired thick putty-like mix.

The wire mesh used as a reinforcement serves to strengthen the pattern and the pattern may be made at a smaller cost than by incorporating a metal match plate in the pattern, as described in my copending application, Serial No. 32,325. The dowe pm holes may be drilled in the fplugs g as at n after the casting is removed rom the mould.

The surface of this pattern issmooth and the stone vis very hard when once set, the stone itself being capable of resisting a considerable number of shocks and strains. The advantage of usin such a stone material is that the same wilI not shrink when' stored away and the pattern may be used over and over again with good results. The stone mould sections designated 10 and 20, may be stored away due to the fact that they will not shrink or absorb moisture. They may be stored for along period of time before being used again and one will be able to then reproduce as erfect castings as before. In Figs. 14 andp 15 I show a modified form of construction in which projections on the pattern may be formed by fitting in metal plugs in the deep recesses in the mould sections. These plugs are provided with tongues or anchoring lugs ypreferably formed integral therewith which are imbedded in the stone (Fig. 15), thereby securely tying'the plugs to the pattern.

What I claim is:

1. A pattern of cast stone and having a wire mesh reinforcement.

2. A pattern of mouldable cementitious material and having a central wire mesh reinforcement around which the cementil tious material is cast.

3. A pattern of mouldable cementitious material and having a wire mesh reinforcement embedded therein which is bent to conform to the parting line.

4. A pattern of mouldable cementitious material and having a wire mesh reinforcement embedded therein which is bent to con` form substantially with the parting line and which is partially slit, the wire mesh adjacent said slit bent into the projecting parts of said pattern to reinforce said projecting parts.

5. A pattern of mouldable cementitious material and having a reinforcement embedded therein, said reinforcement provided with projecting portions located in the prolll f manna a jecting parte of said pattern to reinforce the metal reinforcement cast therein and which same. s'caj able of taking a. set after being dis- 6. A pattern of ,moulded `stone provided torte to conform to the configuration of said l0 with a dlstortable metal reinforcement which stone pattern.

5 is capable of taking a set after beingso dis- In testimony whereof I have aixed my tol-ted.. signature.

7 a A pattern ofcast stone provided with a. LLOYD G. COPEMAN. 

